Counter construction



June 16, 1959 H. E. HANSEN COUNTER CONSTRUCTION 2 Shets-Sheet 1 Filed March 15, 1956 E N A M m H June 16, 1959 H. E. HANSEN 2,890,919

COUNTER CONSTRUCTION Filed March 15, 1956 2 Sheets-Sheet 2 III/II /fl4 his ATTORNEYS United States COUNTER GONSTRUCTION Herman 'E. Hansen, "Winterton,"NlY., assignor to Con- ,goleum-Nairn lnc., 'Kearny, 'N.J., a corporation of New York :ApplicationMarch I5, 1956, SerialNo. 571,689

8 Claims. (CL 311-1-510'6) This inventionrelates to counters and .to component parts :useful in .the construction thereof.

Thedemand .for counters havingisurfaces which are durable, attractive, and :easilymaintained, has resulted in widely increasing use of permanently mounted surfacing? sheets .formed .of such materials :as hardened resin compositions, vinylplastic coated .felt base or the like. lln practice the surfacing-sheets are adhesively laminated to flat backing pieces formed of plywood, for example, and the raw edges of thelaminate finished in any of a number of ways, none entirely satisfactory in all respects.

Depending on the 'type of surfacing sheet material used, and the complexity of the layout, counters are fabricated either on the site using hand tools or in fabricating shops using more elaborate equipment. Presently, factory fabricated and site-fabricated units alike most often utilize externally applied polished metal moulding strips of the-snap-on typeto finish the raw edges. Although economical, external moulding strips represent a source of leakage*which'canloosentheadhesive bond securing the surfacing sheet-and can rot the Wooden sub- StFLlCtll'I'"Of aCOUHteI'. Also, theytend'to collect dirt at the-line of junction with 'the surfacing sheet and, in many applications, form an undesirably conspicuous margin-around-the=entire counterassernbly. It has, of course, been recognized that 'rnetal edgemoulding can be eliminated *by' utiliaing some of the surfacing sheet material to cover'therawedge in "what iscommonly called a selfedge. A liquid-tight, durable self edge has not,

'howeverfbeen attainable"heretofore except by the most "to "provide "improved "counter constructions having self edges of pleasinglywounded contour which are both liquid-tight and durable while at the samewtime capable of simplified fabrication.

Another object of'the invention isto provide an im- ;proved "counter construction, the sub-structure of which can'cornprise conventional, easily worked, wood panels, 'andlthe surfacing of which comprises durable, Water-impervious sheet material uniquely integrated with the substructureito form a completed assemblyin which unbroken extensions of "the surfacing'material define the edges.

.Another object of the invention is :to' provide novel subrstructureform pieces forcontouring a counter framework to receive surface sheeting.

In accordance withthe present invention, a series of form piecesffor defining respectively'the front or leading .edgerof. the counten' the .cove between the fiat working surface of the counter, and the-upright back splash, and the top edge'ofltheback splash, are provided for attachment totl'flat pane'ls to become, together with the ,pancls part of a countersubvstructure defining a smooth, continuous surface to which a singlepiece of surfacing 2,890,919 Patented June 16, 1959 ice sheet material is uadhesively attached to integrate the or externally applied marginal mouldings.

The form piece which defines-"the front edge of the counter can be arranged for application -to the horizontal panel in a simple snap'fit, withithe design being such that once in positionandwith "the surfacing sheet applied it defines anenlarged, gentlyrounded edge which is not susceptible of displacement either angularly or in translation. The cove forming piece is designed in accordance with theinvention to form a junction between the horizontal and vertical panels and includes surfaces complementary toboth panels. In one embodiment, the cove forming piece comprises not only a substructure for backing up the surfacing sheet but a bridging link by means of which thevertical backsplash panel is attached to and carried bythe horizontal panel. The form piece for defining the top of the back 'splash is provided in accordancewith the'invention with a rear wardly extendingflangeby means of which the counter assembly can be scribed intofthe wall in an abutting relationship which eliminates the usual gapsand prevents, it follows, the ingress of liquid, food particles, or the like, down the wall behind lthecounter to points forever inaccessible for washing.

Representative embodiments of the invention are described below having reference to the accompanying drawings in which:

Figure ,1 is a view in perspective of a counter assembly embodying the present invention;

Figure 32 is a view in vertical section of the counter assembly shown in .Figure .1;

Figure 3A is a view'in. perspective with its left hand end. in vertical section of a shortlength .of a. form or contouring piecefor use in fabricating thelfront edge of the counter;

Figure 3B ista viewsimilar to Figure 3A showinga modified form piece ,for the front :edge of the counter;

Figure 4 is a viewsimilar to Figure 3A showing one design .of form piecelfordefining thecove of the counter assembly at the. intersection of the :counter and the back splash;

Figure 5A is a view similarto t Figure 3A showing the form piece for completing the back splash of the counter and for defining a wall junction;

Figure 5B is a view similar to Figure 5A2showing2a modified form piece for completing the back splash of the counterand for defining a wall junction, theform piece being illustrated as mounted on a. fragment of a back panel;

Figure 6 is a fragmentary view. in vertical section illustrating an alternative technique for forming the counter construction; and

Figure 7 is a fragmentary =view in vertical section showing a modified formtof the cove'portion of the counter construction which ."iS particularly useful in the practice of the .counter fabricating technique partially illustrated by Figure 6.

i .As will be apparent from thefollowing description, the present invention is generally applicable to counters such as kitchen counters, bar tops,=table=tops or ;the:like, and certain parts thereof :areaapplica'ble to surfaced stair treads. It has particular utility in the construction of sinkqarea and floor cabinet tops-for kitchens wherein the counter surface is provided with an upright ,backsplash, in which form. it is. illustrated in :theaccompanying drawlllgS.

Referringto Figures 1 .-an"d,2 ,,jthe.coui1ter oflthe present invention, generally indicated by the numeral 10 and shown for purposes of illustration as formed with a cutrial such as metal, and the metal is preferablyof the extrudable type such as aluminum having in its finished form surfaces which are slightly dull, e.g., a satin finish capable of establishing a strong adhesive bond to the overlying surfacing sheet material of the finished counter.

As shown in Figures 2 and 3A, the front edge form piece 14 includes a continuously curving convex outer wall 15, the central inner portion of which is formed with a pair of ribs 16 and 17 adapted to abut the leading edge of the panel 12 along vertically spaced apart lines. The upper portion of the wall 15, which overlies the panel 12,

is formed with a slight reverse curvature 18 to define a feather edge 19 at the line of junction with the panel. The underside of the feather edge 19 is formed with a flat 20 adapted to rest on the panel 12 and rearward of the flat 20 is a depending rib 21 adapted to rest on the panel 12 close to its edge. The lower end of the contoured outer wall terminates in an upwardly extending vertical flange 22 inturned at 23 to form an abutment to engage the underside of the panel 12. As best shown in Figure 2, the form piece 14 surrounds the forward end of the panel 12 so that the feather edge 19 smoothly merges into the upper surface of the panel 12 along a line spaced inwardly from the forward edge thereof with the flat 20 and rib 21 engaging the upper surface. In addition, the ribs 16 and 17 engage the forward edge of the panel and the inturned edge 23 of the flange 22 engages the lower surface of the panel along a marginal line spaced inwardly from the forward edge. Preferably the form piece 15 is so constructed that it must be slightly expanded to fit over the panel edge, the expansion being accommodated by slight flexing of the resilient wall 15. In this fashion, a tight, snap-on fit is assured. The design of the form piece 14 is such that most externally applied forces tend to increase the frictional binding or clamping forces which help to hold it in position on the panel 12. Together with the adhesively applied sheet overlay, as described below, the leading edge construction becomes fully secured against angular and translational displacement.

The modified design for the form piece 14' shown by Figure 33 includes a supplemental securing means in the form of a central barbed flange 24 adapted to be driven 'into a suitable groove (not shown) which is preferably preformed in the leading edge of the panel 12. Parts generally similar to those of Figure 3A are identified by like primed reference characters and, having generally similar functions, need not be described in detail.

Attached to the rear end portion of the panel 12 is a cove forming piece 28. As shown in Figure 4, the cove piece 28 can include a body portion 30 preferably hollow and having a concavely curved exterior surface 32 and flat under surfaces 34 and 36 which form feather edges at either extreme of the concave surface. Extending perpendicularly downward from the surface 36 is a flange 3 8. As shown in Figure 2, the cove piece 28 engages the rear end portion of the panel 12 with the flange 38 flush with the rear edge thereof and the surface 36 abutting the upper surface thereof so that the adjacent feather edge 7 merges smoothly with the upper surface of the panel along which can be formedof any suitable material such as plywood or the like. Fastening means such as nails 44 can be driven through the lower end portion of the back splash panel and into the rear edge of the panel, 12 through the flange 38. If necessary, the flange 38 of the cove piece the numeral 40.

can be apcrtured, as at 42 to receive the fastening means.

The upper edge of the back splash panel 40 has secured thereto a top edgeform piece, different designs of which are illustrated by Figures 5A and 5B. Referring first to Figures 2 and 5A, there is shown a top edge form piece 50 including a convexly curved exterior surface 52 terminating at its upper end in a horizontal, slightly sharpened flange 54 extending rearwardly there from which provides a continuation of the convex exterior surface. At its lower end the piece is formed with an inturned flange or shoulder 56 which rests on the top edge corner of the back panel 40. The piece 50 is completed by a depending back flange 57, internally shouldered at 58 to rest on the othertop edge corner of the back panel 40, and adapted to pass downward along the back Wall of the panel flush therewith. As shown in Figure 2, the back splash top forming piece 50 is secured in position by securing means such as nails 59 passing through the flange 57 to enter the panel 40L The convex exterior surface 52 of the form piece forms a continuation of the forward surface of the panel With the horizontal flange 54 extending beyond the rearward surface thereof to be received, after the sheet surfacing material is applied, in a suitable groove scored inthe wall W against which the counter assembly abuts. 'In this fashion, a gap-free junction results.

As shown by Figure 5B, the top edgeiforrn piece 60 can be modified by the addition of a barbed inner flange 62 depending from a shoulder 64 and adapted to be re ceived in a groove 66 formed in the upper edgeof the back splash panel, a fragment of which is identified by The form piece 60 also includes a convexly curved wall 70 terminating at its lower, forward end in a surface to rest on the forward corner edge of the back splash panel 40' and terminating at its rearward, upper end in a horizontal wall engaging flange 72. Extending downward from the underside of the wall 70 is a flange 74, the free end of which rests on the back corner edge of the back splash panel 40.

It can thus be seen that the assembled panels 12 and 40 or 40 with the three form pieces 14, 28 and 50 or 60 attached thereto provide a smooth, continuous exterior sin-face which extends from the front edge of the counter to the top of the back splash. As stated, preferably each of the form pieces is formed with non-polished, i.e., satin finish surfaces for purposes now to be described.

Intimately bonded with the exterior surfaces of each of the pieces 14, 28 and 50 and the mutually perpendicular flat surfaces of the two panels 12 and 40 is a single thin, e.g., ,4 thick, sheet of water impervious material 76, such as plastic or the like. The sheet material is preferably flexible under normal conditions and can take the form, for example, of a felt base product coated with a vinyl plastic or it can take the form of a solid plastic sheet. Adhesive is spread uniformly over all of the surfaces. The sheet material is preferably pressed into position so that voids do not occur between it and its supporting surfaces. In position, it will be understood that the sheet 76 imparts additional strength to the counter assembly. In particular, the sheet assists in securing the front edge form piece 14 against translational movement off of the panel 12 in the direction of the plane of the panel. The side edges of the finished counter assembly, if exposed, can be covered by suitable exposed cover pieces 78, 80, 82, 84 and 86, as shown by Figure 1, which can be of the conventional snap-on type.

A method and an apparatus or tool for applying the surfacing sheet material 76 to the sub-structure assembly discribed above are disclosed in the copending application, Serial No. 571,653, filed March 15, 1956. In accordance with the disclosure of that application, the sheet of surfacing material is cut and fitted in a single piece to the counter surface. Next a suitable adhesive is applied between the exterior counter surface and the underside of the sheet, preferably by applying the adhesive sepa- 1T5 'rately toboth'surface's. After the adhesive has beenapplied the sheet is brought into registry with the substructure and pressed into position, using, for --example, the matrix or tool of said "copending applicationtobring the sheet and sub-structure 'into intimate relationship throughout, the singlesheet thereby being bonded to the exposed surfaces of the several panel and form (pieces alike.

Another example 'of a material which can be utilized in conjunction with thetpresentinvention, is the so-called C-stage plastic materials of the-type comprising laminated sheets, such as, for example, paper 'woven fabric and matteror woven glass fibers impregnated with any suitable thermosetting resin such -as phenol urea melamine formaldehyde resins and their derivates including the :group of unsaturated polyester resins, e.g., ethylene glycolmaleate acid, polymer modified with mono'meric styrene. -Such plastics are commercially available as formed, suitable adhesives of the type mentioned above are then applied in the same manneras previously indicated. The sheet is then engaged to the counter surface and thernauix appned anduarn'peu in'the manner iridi- Referring now to Figures 6 and 7, an alternative fabrieating technique and a modified cove forming piece are illustrated. A back splash panel 88 can, as a preliminary step in the fabrication of the counter, first be disposed in the plane of the horizontal panel 90 and spaced edgewise therefrom for a predetermined distance to receive a flat, unbent sheet 92 of surfacing material, adhesive being applied between the opposed surfaces. After the adhesive has set, the black splash panel 88 is swung into a plane normal to that of the panel 90 by flexing the bridging strip of the sheet material into a generally rounded curvature to define the cove. Next, a reinforced form piece 94 is inserted behind the sheet material at the cove and is secured to both the horizontal and vertical panels. The form piece 94 includes a concavely rounded center wall 96 terminating at its respective ends in reinforced mutually perpendicular shoulders 98 and 109 which abut the edges of the panels 88 and 90, respectively. Marginal flanges 102 and 104 can be formed at the ends of the shoulders 98 and 100 respectively to overlie the panels 88 and 90 and to set the position of the form piece 94 so its curved surface 96 precisely backs up the sheet material 92 at the cove. A barbed flange 106 can be formed on the shoulder 106 to be driven into a suitable channel or groove 108 formed in the horizontal panel 90, after which suitable securing means 110 such as nails, screws, or the like, can be driven into the edge or side, as the case may be, of the back panel 88. It will be seen, therefore, that the form piece 94 serves as both a cove defining member and as a structural link between the two panels.

It can thus be seen that there has been provided a counter which may be easily constructed without the need of expensive tools or machines. Of particular significance is the fact that the counter presents a smooth, continuous, water impervious surface, thereby eliminating the need for exposed moulding strips. As noted above, the use of such exposed moulding strips presents the disadvantage of dirt collection and leakage so that with the counter of the present invention, these disadvantages are effectively overcome. It should also be noted that the rearwardly extending horizontal flange 54 of the back splash form piece provides an effective means whereby the counter maybe installed against a wall so as to insure a leakproof fit. It is well known that most walls are not precisely flat and include undulations, dips and the like. Heretofore, it has been foundnecessary to either shape the back splash panel of the counter to the wall or provide caulking between the space between the wall and the back splash panel, which procedures have obvious disadvantages. With the present invention, the counter is initially placed against the wall so that the end of the flange 54 engages the same. The wall is then scored or grooved along the flange and this scoring is repeated until a horizontal groove is formed in the wall which is-suitable to receive the flange with the rear surface of the back splash panel abutting the wall. In this manner, there is provided a horizontal surface which intersects the walk-the horizontal surface being-impervious to water and shaped to direct the water downwardly away from the wall;

It will be appreciated that various modifications can be'madein the invention as described above without in any way deviating from-thescope-thereof as defined inthe appended claims.

Iclaim: 1. A bonded surface construction comprising a horizontal panel, an elongated form piece secured to the panel adjacent the forward edge thereof, and a thin, continuous sheet of flexible surfacing material intimately from the surface of the upper portion and surrounding the edge of the panel, inner shoulder means to engage the forward edge of the panel, and lower shoulder means to engage the undersurface of the panel inwardly from its edge.

2. A bonded surface construction comprising a horizontal panel, an elongated form piece secured to the panel adjacent the forward edge thereof, and a thin, continuous sheet of flexible surfacing material intimately bonded to both the surfaces of the panel and form piece, said form piece comprising a single piece of rigid material including an upper portion overlying the upper surface of the panel, said upper portion being a gently concavely curved surface and merging smoothly in a feather edge into the plane of the panel along a line spaced inwardly from the panel edge, a forward portion on the form piece including a convex surface continuing in an unbroken line from the surface of the upper portion and surrounding the forward edge of the panel to define a reverse curvature with said concavely curved upper portion, inner shoulder means to engage the edge of the panel, lower shoulder means to engage the undersurface of the panel inwardly from its edge, said upper and forward portions of the form piece being slightly flexible, whereby said upper portion and lower shoulder portion embrace the panel tightly therebetween, said inner shoulder means engaging the forward edge of the panel, precluding angular movement of the form piece on the panel.

3. A bonded surface construction as set forth in claim 2, said upper portion on its under side including a flat to rest on the panel adjacent the feather edge, and shoulder means to engage the upper surface of the panel closely adjacent the forward edge thereof.

4. A contoured form piece for attachment to a panel to define an enlarged rounded rigid edge thereon to afford a gently curving surface merging with a surface of the panel to support a continuous sheet of flexible surfacing material bonded to both the panel and the form piece, said form piece comprising as an integral unit an upper portion adapted to overlie one surface of the panel, said upper portion having a feather'edge adapted to engage the surface of the panel in a line spaced inwardly from the panel edge, a convexly curving portion forming a continuation of the surface of the upper portion to define a surface rounded to extend to a point spaced inwardly from the panel edge and below the lower surface of the panel, inwardly extending shoulder means adapted to engage the edge of the panel, and upwardly extending shoulder means to engage the lower surface of the panel along a line inwardly from the edge.

5. A contoured form piece as set forth in claim 4, including shoulder means on the under side of the upper portion to engage the upper surface of the panel, the distance between the last said shoulder means and said inwardly extending shoulder means being slightly less than the thickness of the panel edge, whereby the form piece must be expanded to accommodate the panel.

6. A contoured form piece for attachment to a panel to define an enlarged rounded rigid edge thereon to afford a gently curving surface merging with a surface of the panel to support a continuous sheet of flexible surfacing material bonded to both the panel and the form piece, said form piece comprising as an integral unit an upper portion adapted to overlie one surface of the panel and formed with a reversely curved, slightly concave exposed surface to define a feather edge adapted to engage the surface of the panel in a line spaced inwardly from the panel edge, a convexly curving portion forming a continuation of the surface of the upper portion to define a surface rounded to extend to a point spaced inwardly from the panel edge and below the lower surface of the panel, an inwardly extending shoulder adapted to engage theedge of the panel and an upwardly extending shoulder to engage the lower surface of the panel along a line inwardly from the edge, and securing means to join the form piece to the panel.

8 7. Acontour ed form piece as set forth in claim 6, said upper portion including on its lower side a fiat adjacent the feather edge and a shoulder to engage the panel closely adjacent the panel edge.

8. A contoured form piece for attachment to an edge of a panel to define an enlarged rounded surface around the edge of the panel comprising a single piece of rigid material including an upper portion overlying the upper surface of the panel and merging smoothly in a feathered edge into the plane thereof along a line spaced inwardly from the panel edge, a forward portion of the form piece continuing in an unbroken line from the surface of the upper portion and passing around the edge of the panel from above the upper surface of the panel to below the under surface thereof, inner shoulder means to engage the forward edge of the panel, and an upstanding lower portion, the upper edge of which forms a lower shoulder which engages the under surface of the panel, the upper portion of the form piece and the lower shoulder defining a gap therebetween to receive the edge of the panel in registered engagement with the inner shoulder means,

References Cited in the file of this patent UNITED STATES PATENTS 1,768,731 Awbrey July 1, 1930 2,509,037 Flicker May 23, 1950 2,570,850 Pearson Oct. 9, 1951 2,614,014 Stanitz Oct. 14, 1952 2,626,846 Morris Jan. 27, 1953 2,646,326 Stanitz July 21, 1953 2,654,648 Burke Oct. 6, 1953 2,665,182 Stanitz Jan. 5, 1954 2,702,221 Hammer Feb. 15, 1955 2,743,980 Hobbs May 1, 1956 

